Automated fiber optic connectorization apparatus and method

ABSTRACT

A method and apparatus is provided for mounting any one of a plurality of types of connectors upon the end portion of a fiber optic cable. The automated fiber optic connectorization apparatus includes a memory device for storing data relating to a plurality of types of connectors. The automated fiber optic connectorization apparatus also includes a controller for receiving input from a system operator or other source that specifies the type of connector to be mounted upon the specified fiber optic cable, the polishing geometry, and the optical performance specifications. Based upon this input, the controller determines the components required to mount the specified type of connector upon the end portion of the fiber optic cable based upon the data stored by the memory device. The automated fiber optic connectorization apparatus also includes means for obtaining the necessary components and means for assembling these components upon the end portion of the fiber optic cable. Therefore, the automated fiber optic connectorization apparatus can automatically mount the specified type of connector upon the end portion of the fiber optic cable. The automated fiber optic connectorization apparatus can also include means for polishing the end face of the optical fiber and means for automatically inspecting the optical fiber after the end face of the optical fiber has been polished, but prior to mounting the connector upon the end portion of the optical fiber. The automated fiber optic connectorization apparatus can also test the optical performance of the connectorized fiber optic cable.

FIELD OF THE INVENTION

[0001] The present invention relates generally to a method and apparatusfor connectorizing, testing and inspecting fiber optic cables and, morespecifically, a method and apparatus for automatically connectorizing,testing and inspecting fiber optic cables.

BACKGROUND OF THE INVENTION

[0002] Fiber optic networks are employed in an increasing and variednumber of applications for transmitting voice, data and otherinformation. For example, fiber optic networks are utilized in a widevariety of aerospace applications for transmitting data at high speedsand with relatively low loss. Each of these fiber optic networksincludes a number of optical fiber links. In turn, each optical fiberlink generally includes a fiber optic connector mounted to the opposedends thereof. This connectorization process is further complicated sinceeach end face of the optical fiber must generally be precisely polishedand cleaned after mounting the ferrule, but before mounting theremainder of the connector thereon. Thus, there is a risk of losing thisexpensive ferrule, if the polishing process is not successful. Theindustry's failure rate of polishing is approximately 10% and the costof each ferrule, such as ITT Cannon part number NFOC-F15PB, is $150. Inaddition, the connectorized optical fiber must oftentimes be inspectedto insure compliance with performance specifications thereby furtherincrease on labor costs. As a result, it typically takes approximately20 minutes to manually connectorize one end of a fiber optic cable.

[0003] Current techniques for mounting connectors upon the end portionsof fiber optic cables are generally quite complicated and laborintensive and may oftentimes require specially trained technicians andinspectors. As a result, the connectorization costs may quickly becomeunnecessarily large, particularly in view of the large number of fiberoptic cables that must typically be connectorized by an aircraftmanufacturer. In addition, current connectorization techniques oftenhave poor repeatability, thereby producing fiber optic cables which havea wide variety of operating characteristics.

[0004] A number of automated techniques have therefore been developedfor automatically mounting connectors upon the end portions of a fiberoptic cable. For example, U.S. Pat. No. 5,394,606 to Isamu Knoshita, etal. and U.S. Pat. No. 4,944,079 to Kunio Nakamura, et al. describeautomated devices for connectorizing a fiber optic cable. Unfortunately,each of these automated techniques is limited to mounting one particulartype of connector upon the end portion of a common fiber optic cable andis not designed to mount the wide variety of connectors upon the endportions of respective different fiber optic cables that are demanded bymany modern applications, such as aerospace and local area network (LAN)applications.

SUMMARY OF THE INVENTION

[0005] It is therefore an object of the present invention to provide animproved method and apparatus for automatically connectorizing fiberoptic cables.

[0006] It is another object of the present invention to provide a methodand apparatus for automatically mounting any one of a variety ofconnectors upon the end portion of a fiber optic cable.

[0007] It is a further object of the present invention to provide animproved method and apparatus for automatically inspecting andclassifying optical fibers during the connectorization process.

[0008] It is yet another object of the present invention to provide animproved method and apparatus for automatically testing the opticalperformance of a fiber optic cable after the connectorization process.

[0009] These and other objects are provided, according to one embodimentof the present invention, by a method and apparatus for mounting any oneof a plurality of types of connectors upon the end portion of a fiberoptic cable. According to this embodiment, the automated fiber opticconnectorization apparatus includes a memory device for storing datarelating to a plurality of types of connectors, such as the parts andsupplies required to assemble each type of connector, and data relatingto the fiber end-face geometry and corresponding optical performancedata. The automated fiber optic connectorization apparatus also includesa controller for receiving input data that describe the detailedrequirements for each fiber optic link, such as from a system operator,a wire data list, or other source, that specifies the type of connectorto be mounted upon the end portion of the optical fiber. Based upon thisinput, the controller determines the components, i.e., the parts andsupplies, required to mount the specified type of connector upon the endportion of the fiber optic cable based upon the data stored by thememory device. The automated fiber optic connectorization apparatus alsoincludes means for obtaining the necessary components and means forassembling these components upon the end portion of the fiber opticcable. As a result, the automated fiber optic connectorization apparatusof this embodiment of the present invention can automatically mount thespecified type of connector of the type upon the end portion of thefiber optic cable.

[0010] In addition to inputting the type of connector, the systemoperator, wire data list, or other source can also specify the length ofthe resulting fiber optic cable. Accordingly, the automated fiber opticconnectorization apparatus of one embodiment includes a cutter forautomatically cutting and stripping the cable components to varyinglengths. Notably, the automated fiber optic connectorization apparatuscan also include means for automatically polishing the end face of theoptical fiber and inspecting the end face prior to mounting theconnector upon the end portion of the optical fiber. Thus, the task ofmounting the connector proceeds only if the polished surface of thefiber end-face has been inspected and is found to be acceptable.

[0011] To handle this task, a cassette is also provided for preparingthe end face of an optical fiber, such as for polishing or cleaning theend face of an optical fiber. The cassette includes a housing defining awindow and a supply reel and a take up reel disposed within the housing.The cassette contains preparatory tapes, such as a polishing strip and acleaning strip, that advances from the supply reel to the take up reelfor preparing the end face of the optical fiber. Further, the cassetteincludes means for directing the tape by the window defined by thehousing such that the tape contacts and prepares the end face of theoptical fiber, such as by polishing or cleaning the end face of theoptical fiber. For example, the directing means can include a resilientpad aligned with the window defined by the housing and disposed interiorof the preparatory tape within the housing for supporting thepreparatory tape during contact with the end face of the optical fiber.In order to properly prepare the end face of the optical fiber, thecassette also preferably includes means for controllably moving thehousing relative to the end face of the optical fiber.

[0012] The automated fiber optic connectorization apparatus can alsoinclude means for automatically inspecting the optical fiber after theend face of the optical fiber has been polished. According to thisembodiment, an automated optical fiber inspection apparatus is providedfor automatically inspecting and classifying the polished end face of anoptical fiber before proceeding to the next step, i.e. prior toconnectorizing the fiber optic cable. According to this embodiment, theautomated optical fiber inspection apparatus includes a memory devicefor storing predefined data sets relating to at least one characteristicof the end face of the optical fiber. For example, the data sets can berepresentative of images of acceptable end faces and unacceptable endfaces.

[0013] The automated optical fiber inspection apparatus of thisembodiment can also include an imaging system for obtaining an image,preferably a composite image generated from a series of captured images,characterizing the end-face contour of the optical fiber and means forcomparing this composite image of the end face of the optical fiberagainst the predefined data sets relating to at least one characteristicof the end face of the optical fiber so as to automatically determinethe “best-match” data set. Since each predefined data set has beenclassified as acceptable or unacceptable, the automated optical fiberinspection apparatus determines the acceptability of the end-facecontour based upon the classification of the best-match data set.According to one advantageous embodiment, the automated optical fiberinspection apparatus can also include means for automaticallydetermining if an unacceptable optical fiber can be corrected, such asby repolishing, or if the unacceptable optical fiber must be completedreworked, beginning by recleaving the end portion of the optical fiber.The automated optical fiber inspection apparatus can also include means,such as a test station, for testing the connectorized fiber optic cableto guarantee predefined optical operating parameters, such as opticalloss or optical back-reflection.

[0014] During the process for automatically inspecting andconnectorizing a fiber optic cable, the fiber optic cable is preferablycarried by an optical fiber cartridge assembly which presents theappropriate segment of the fiber optic cable for jacket stripping, fibercleaving, and end-face polishing operations. According to thisembodiment, the optical fiber cartridge assembly includes an opticalfiber cartridge including a platform, a reel rotatably mounted upon theplatform, and first and second gripping means mounted upon the platformfor holding the first and second opposed ends of the optical fiber,respectively. The optical fiber cartridge of this embodiment alsoincludes means for rotating the platform relative to the reel such thatthe optical fiber is wound about the reel. In this regard, the opticalfiber cartridge can include means for raising the reel relative to theplatform during the rotation of the platform relative to the reel.

[0015] By providing for the automatic connectorization of fiber opticcables, the automatic fiber optic connectorization method and apparatusof the present invention significantly reduces the time and laborrequired to mount connectors upon the end portions of fiber opticcables, thereby increasing productivity. As a result, the automatedfiber optic connectorization apparatus can be readily operated bytechnicians with very little training. The efficiency and yield of theautomatic connectorization process of the present invention is furtheradvanced by the automated optical fiber inspection apparatus of oneembodiment that insures that the optical fibers have been properlypolished prior to mounting of the expensive connectors and, if anoptical fiber is unacceptable, automatically determines if the opticalfiber must be repolished or otherwise reworked. In contrast toconventional automated connectorization techniques, the automated fiberoptic connectorization apparatus of the present invention canadvantageously mount any one of a plurality of types of connectors uponthe end portion of a fiber optic cable based upon input by the systemoperator or other source, thereby permitting rapid customization of theautomated fiber optic connectorization apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]FIG. 1 is a perspective view of an automatic fiber opticconnectorization apparatus of one embodiment of the present invention.

[0017]FIG. 2 is a block diagram of one advantageous embodiment of theautomatic fiber optic connectorization apparatus of the presentinvention.

[0018]FIGS. 3A and 3B are perspective views of the optical fibercartridge assembly of two advantageous embodiments of the presentinvention.

[0019]FIGS. 4A and 4B are end and plan views, respectively, of a gripperaccording to one embodiment of the present invention.

[0020]FIGS. 5A and 5B are plan views of an optical fiber cartridgeaccording to one embodiment of the present invention that illustratesthe winding of fiber optic cable upon the reel of the optical fibercartridge.

[0021]FIG. 6A is an overall block diagram of the operations performed bythe automatic fiber optic connectorization apparatus of one embodimentof the present invention.

[0022]FIG. 6B is a block diagram of the operations performed to preparea fiber optic cable according to one embodiment of the presentinvention.

[0023]FIG. 6C is a block diagram of the operations performed to test andverify product conformity according to one embodiment of the presentinvention.

[0024]FIG. 6D is a block diagram of the operations performed to grindand polish the end face of an optical fiber according to one embodimentof the present invention.

[0025]FIG. 6E is a block diagram of the operations performed to inspectthe end face of an optical fiber according to one embodiment of thepresent invention.

[0026]FIG. 6F is a block diagram of the operations performed to mount aconnector upon the end portion of a fiber optic cable according to oneembodiment of the present invention.

[0027]FIG. 6G is a block diagram of the operations performed to inspecta connectorized fiber optic cable according to one embodiment of thepresent invention.

[0028]FIG. 7 is a perspective view of an end portion of a fiber opticcable in which the various layers have been partially removed orstripped for purposes of illustration.

[0029]FIGS. 8A and 8B are perspective and fragmentary perspective viewsof a cassette for preparing the end face of an optical fiber accordingto one embodiment of the present invention.

[0030] FIGS. 9A-9D depict four phase shift images (or interferrograms)with phase shifts of π/2, π, 3π/2 and 2π, respectively.

[0031]FIG. 9E is a composite phase shift image based upon the four phaseshift images of FIGS. 9A-9D.

[0032]FIG. 10 is a representation of the phase shift analysis and theprocess of generating first a composite phase image from the four phaseshift images and then a normalized phase patten from the maximum andminimum values of the composite phase image according to one embodimentof the automated optical fiber inspection apparatus of the presentinvention.

[0033]FIGS. 11A and 11B are digitized composite images before and afteredge enhancement, respectively, which enhance the distinctive pattern ofan image which otherwise may be obscured due to the blurring boundariesof the features.

[0034] FIGS. 12A-12D are a composite image and related contour maps ofan end face of an optical fiber having a minor defect that iscorrectable by further polishing.

[0035] FIGS. 13A-13D are a composite image and related contour maps ofan end face of an optical fiber having a serious defect that cannot becorrected by further polishing.

[0036]FIG. 14 is a schematic diagram of the automated optical fiberinspection apparatus of one embodiment of the present invention.

[0037]FIG. 15 is a block diagram of the operations performed by oneadvantageous embodiment of the automatic optical fiber inspectionapparatus of the present invention.

[0038] FIGS. 16A-16C show the end faces of various optical fibers thatmay be corrected by further polishing.

[0039] FIGS. 17A-17F show the end faces of various optical fibers thatcannot be corrected by further polishing.

[0040]FIG. 18 is a block diagram of the operations performed todetermine if an end face of an optical fiber is acceptable according toone embodiment of the present invention.

[0041]FIG. 19 is a schematic view of the optical performance testingapparatus according to one advantageous embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0042] The present invention now will be described more fullyhereinafter with reference to the accompanying drawings, in whichpreferred embodiments of the invention are shown. This invention may,however, be embodied in many different forms and should not be construedas limited to the embodiments set forth herein; rather, theseembodiments are provided so that this disclosure will be thorough andcomplete, and will fully convey the scope of the invention to thoseskilled in the art. Like numbers refer to like elements throughout.

[0043] Referring now to FIG. 1, an automatic fiber opticconnectorization apparatus 20 is illustrated. Although the automaticfiber optic connectorization apparatus is not unusually large, it isanticipated that the actual size of the automated fiber opticconnectorization apparatus will be further reduced with further advancesin miniaturization techniques. As explained below, the automatic fiberoptic connectorization apparatus processes raw optical fiber based uponinput provided by the system operator or other source, such as acomputer network or another type of external computer, to produce afiber optic cable that is cut to length and that has been connectorizedwith the appropriate connectors and inspected. Moreover, the automaticfiber optic connectorization apparatus tests the optical fiber duringand following to connectorization process to insure compliance withperformance specifications.

[0044] As shown in block diagram form in FIG. 2, the automatic fiberoptic connectorization apparatus 20 preferably includes a centralcomputer 22 that operates under software control to perform the variousfunctions shown in FIG. 2 and described hereinbelow. Although theautomatic fiber optic connectorization apparatus can include manydifferent types of central computers, the central computer of oneadvantageous embodiment is an Intel Pentium processor operating at 120MHz or higher processing speeds. The central computer includes or isotherwise associated with a memory device 24 for storing a variety ofdata. In particular, the memory device stores data input by the systemoperator or other source as well as data downloaded from a fiber opticcable and connector database 26, i.e. a wire data list. As shown in FIG.2, for example, the system operator enters data via a fiber optic cableconfiguration workstation 28. In turn, the fiber optic cableconfiguration workstation accesses the fiber optic cable and connectordatabase and provides the computer with the appropriate data forconstructing the cable specified by the system operator. Although thefiber optic cable and connector database is depicted to be external tothe central computer, the fiber optic cable and connector database ispreferably stored in memory within the central computer. In addition,although a fiber optic cable configuration workstation is provided forentry of data by the system operator, the necessary data can bedownloaded or otherwise provided by another computer system withoutdeparting from the spirit and scope of the present invention.

[0045] Although a wide variety of data can be provided by the systemoperator or downloaded from a wire data list or other source, the datatypically includes the length of the fiber optic cable, the connectortype for each end of the fiber optic cable, the type of optical fiberand/or fiber optic cable, the finished fiber geometry requirements andthe optical performance requirements, such as optical loss and opticalback reflection. The finished fiber geometry requirements generallydepend upon the type of polish, i.e., physical contact or convex method,flat polish or concave polish. With each type of polish, the datapreferably provides the angular tolerance. However, the data alsoprovides the depth of a concave polish, the height of a flat polish andthe radius of curvature and height (apex) of an optical fiber having aconvex end face.

[0046] In the illustrated embodiment, the central computer 22 passesdata and control information to a programmable controller 30, such as anactuator controller or a micro-positioner, which controls the varioushardware components of the automatic fiber optic connectorizationapparatus 20. Preferably, the controller has a flexible datainput/output interface that can receive various data inputs, e.g.,downloaded from a wire list, relating to a variety of fiber optic linkcharacteristics including length, loss, back reflection, connector type,component parts, cable type, fiber size and internal adaptive component,i.e., the type of robotic connector adapter for holding and moving theconnector during the various operations. Although the controller isdepicted to be separate from the central computer, the central computermay include the controller without departing from the spirit and scopeof the present invention. Once the central computer has receivedinstructions from the system operator or other source, the centralcomputer converts the raw data to precise control commands for eachconnectorization step such as marking cable cut length, end striplengths, epoxy application, or fiber polishing, as described below. Thecontroller feeds the raw fiber optic cable into a cable cutting andmarking unit 32, either directly or by first winding the fiber opticcable onto an optical fiber cartridge 34 which is then moved into analigned position relative to the cable cutting and marking unit.

[0047] As shown in FIGS. 3A and 3B, the optical fiber cartridge 34includes a platform 36 and a reel 38 rotatably mounted upon theplatform. The hub 42 of the reel must also be of sufficient diameter toprevent the fiber optic cable from bending more sharply than thepredetermined bend radius of the fiber optic cable. For example, the hubof the reel of one advantageous embodiment has a diameter of at least 4inches.

[0048] The optical fiber cartridge 34 also includes first and secondgripping means mounted upon the platform 36 for holding the first andsecond opposed ends of the optical fiber, respectively. As shown inFIGS. 4A and 4B, each gripping means preferably includes a gripper 44for receiving and securely holding the fiber optic cable and, morepreferably, first, second and third grippers for holding the variousstripped sections of the fiber optic cable, such as the bare opticalfiber, the optical fiber surrounded by a buffer layer (inner jacket) andthe cable jacket (outer jacket), respectively. Preferably, each gripperis designed to grip the entire range of dimensions for the respectivecable component. For example, the third gripper 44′ is preferablydesigned to hold the cable jacket of fiber optic cables having adiameter of 0.9 mm to 3.5 mm, while the first gripper is preferablydesigned to hold bare fibers ranging from 35 microns to 250 microns indiameter.

[0049] With reference to FIGS. 3 and 4, each gripper 44 of oneadvantageous embodiment preferably has a pair of opposed gripper arms 44a, 44 b for engaging the respective cable component, such as the outerjacket of the fiber optic cable, the buffered optical fiber or the bareoptical fiber. In order to securely engage the respective cablecomponent, the first gripper arm can include a recessed or V-shapedsection, while the second gripper arm can include a correspondingV-shaped protruding section. Each gripper can also include a respectiveactuator 46 for opening and closing the pair of opposed gripper arms. Inorder to further control the movement of the gripper arms, each grippercan include one or more rails 48 along which the gripper arms move.Although the grippers are shown to include actuators, the grippers caninclude a variety of other means for biasing the pair of opposed gripperarms into contact with the respective cable component. For example, thegrippers can include one or more springs for biasing the protrudingsection of the second gripper arm into the recessed section of the firstgripper arm so as to securely hold the respective cable componenttherebetween.

[0050] In one advantageous embodiment, the third gripper 44′ designed toengage the cable jacket is mounted upon an adjustable platform 49 thatis supported above the platform 36 of the optical fiber cartridge 34 bymeans of a second set of rails 53. As shown in FIGS. 3A and 3B, thethird gripper also preferably includes a second actuator 50 for movingthe adjustable platform relative to the platform of the optical fibercartridge. By opening the first and second grippers designed to hold thebare optical fiber and the buffered optical fiber while concurrentlyengaging the cable jacket with the third gripper, the fiber optic cablecan be moved relative to the platform of the optical fiber cartridge byadvancing or retracting the second actuator. As such, the end portion ofthe fiber optic cable can be extending beyond the optical fibercartridge, if so desired. The actuators associated with the first,second and third grippers are preferably controlled by the centralcontroller 30 so as to precisely position the fiber with respect to thecable for a variety of cable and fiber diameter combinations.

[0051] In order to begin the cable and fiber preparation processreferenced by block 200 of FIG. 6A, fiber optic cable is first woundupon the optical fiber cartridge 34. Initially, the controller 30actuates a cable feeder 51 to feed a first end of the fiber optic cablefrom the rear of the cartridge through the first, second and thirdgrippers 44 of the first gripping means as shown in FIG. 5A. In theembodiment of FIG. 3A in which the platform includes a sidewall 52, thefirst end of the fiber optic cable is also extended out through anopening 54 defined in the sidewall. The first, second and third grippersof the first gripping means then securely grip the first end of thefiber optic cable.

[0052] The optical fiber cartridge assembly 34 also includes means, suchas an externally engaged rotating driver motor, for rotating theplatform 36, in response to a command from the controller 30, so as towind the predetermined length of fiber optic cable about the reel. Asshown in the embodiment of FIG. 3A, the platform can include taperedsidewalls 52 that increase in height from the rear of the cartridgetoward the front of the cartridge to guide the fiber optic cable overthe grippers 44 while the fiber optic cable is being wound upon thereel. However, the platform need not include sidewalls. Instead, theoptical fiber cartridge assembly can include means, such as an axle 56having a telescoping shaft, for raising the reel relative to theplatform as shown in FIG. 3B during the rotation of the platform suchthat the fiber optic cable passes over the grippers while being woundupon the reel. Once the predetermined length of fiber optic cable iswound upon the reel of this embodiment, the reel is lowered onto theplatform and secured at a fixed position.

[0053] Typically, the controller 30 initiates rotation of the platform36 which continues until the predetermined length of fiber optic cableis wound upon the reel. Thereafter, the rotating means, under control ofthe controller, halts rotation of the optical fiber cartridge with theoptical fiber cartridge facing in the opposite direction so as toposition the fiber optic cable over the first, second and third grippers44 of the second gripping as shown in FIG. 5B.

[0054] The cable cutting and marking unit 32 of the automatic fiberoptic connectorization apparatus 20 includes a cutter 58 responsive tocommands from the controller. The cutter is designed to cut the cablenear the forward edge of the optical fiber cartridge 34 once thepredetermined length of fiber optic cable is wound upon the reel 38 toform a second end that extends loosely from the reel. The controller 30then rotates the reel relative to the optical fiber cartridge to retractthe second end of the fiber optic cable toward the rear of the opticalfiber cartridge until the second end of the fiber optic cable isrearward of the third gripper 44′ of the second gripping means. Thecontroller then reverses the direction of rotation of the reel such thatthe second end of the fiber optic cable is pushed through the first,second and third grippers of the second gripping means so as to extendto the forward edge of the optical fiber cartridge. In the embodiment ofFIG. 3A in which the platform includes a sidewall 52, the first end ofthe fiber optic cable is also extended out through another opening 60defined in the sidewall. The first, second and third grippers of thesecond gripping means then engage the second end of the cable. Theoptical fiber cartridge loaded with the predetermined length of fiberoptic cable and having both end portions held by respective grippers maythen be transported by robotic arm or other means throughout the variousunits of the automatic fiber optic connectorization apparatus forprocessing.

[0055] Once the fiber optic cable has been wound upon the reel 38 andhas been cut to the specified length as shown in block 201 of FIG. 6B,the cable cutting and marking unit 32 of the automatic fiber opticconnectorization apparatus 20 marks the fiber optic cable. See block202. For example, the cable cutting and marking unit can mark the fiberoptic cable with a part number provided by the system operator or thefiber optic cable and connector database 26. In addition, the cablecutting and marking unit can affix installation and/or terminationinformation labels to one or both ends of the fiber optic cable tofacilitate subsequent installation of the fiber optic cable.

[0056] The automatic fiber optic connectorization apparatus 20 alsoincludes a cable stripping unit 62 for stripping the end portion of thefiber optic cable such that the strength members, the coating buffer andthe optical fiber extend beyond the outer jacket by respectivepredetermined strip lengths. See also blocks 203-206 of FIG. 6B. Asknown to those skilled in the art, the predetermined strip lengths bywhich the strength members, the coating buffer and the optical fiberextend beyond the outer jacket are determined based upon the type ofconnector to be mounted upon the end portion of the fiber optic cableand the connectorization procedure. Typically, the central computer 22accesses the fiber optic cable and connector database 26 to determinethe diameter and correct strip length for each cable component once thetype of fiber optic cable and the type of connector to be mounted uponthe end portion of the fiber optic cable has been input. As such, theautomatic fiber optic connectorization apparatus of the presentinvention allows a unique advancement by polishing the fiber to acritical length suitable for each connector type and then preciselysecuring the fiber within the connector ferrule for the desiredcombination of connector and fiber endface geometry.

[0057] The automatic fiber optic connectorization apparatus 20 isdesigned to mount a variety of types of connectors upon a variety oftypes of fiber optic cables. For mounting a connector upon a particulartype of fiber optic cable, the central computer 22 must generally obtainthe respective diameter of each cable component from the fiber opticcable and connector database 26 since different types of fiber opticcables have cable components with different diameters. Referring now toFIG. 7, for example, a single mode fiber optic cable 64 is illustratedwhich has an optical fiber 66 having a core that is approximately 6microns in diameter and a cladding layer that is approximately 125microns in diameter. As shown, the fiber core and cladding areoftentimes encased in a coating or polyamide buffer 70 having a diameterof approximately 174 microns that is, in turn, surrounded by a cablejacket 72, typically formed of a flouropolymer, polyvinylchloride (PVC)or polyurethane. It should be apparent that the foregoing dimensions areprovided for purposes of example and not limitation since there are anumber of other standard sizes of fiber optic cables, such as fiberoptic cable having a core diameter of approximately 100 microns and acladding diameter of 140 microns and fiber optic cables can include acore diameter of 400 microns and a cladding diameter of 480 microns.Although not shown, many fiber optic cables include strength members,typically formed of fiberglass or KEVLAR, that extend between the cablejacket and the buffer. In addition, although a fiber optic cable oftight tube construction is illustrated, the method and apparatus of thepresent invention could also be utilized in conjunction with fiber opticcables having a loose tube construction.

[0058] In order to strip the desired amount of each of the cablecomponents from the end portion of the fiber optic cable, the fiberoptic cable is positioned such that the end portion extends beyond therespective grippers 44. In this regard, the controller 30 commands thefirst and second gripping means to temporarily release the fiber opticcable and the reel 38 is rotated so as to extend one end portion of thefiber optic cable beyond the respective grippers by a preferred amount.The grippers then re-engage and hold the fiber optic cable in placeduring the stripping process. In order to strip the other end portion ofthe fiber optic cable, the grippers are again opened and the reel isrotated in the opposite direction such that the other end portion of thefiber optic cable extends beyond the respective grippers by a sufficientamount prior to again closing the grippers.

[0059] As shown in FIG. 2 and in more detail in FIG. 7, the automaticfiber optic connectorization apparatus 20 also includes a fiber cleavingunit 74, including a scribe, for cleaving the end portions of the fiberoptic cable in order to provide a suitable end face. See block 206 ofFIG. 6B. In order to properly cleave the end portion of the fiber opticcable such that the end face is perpendicular to the longitudinal axisof the fiber optic cable, the fiber optic cable must be preciselypositioned relative to the scribe. Thus, the automatic fiber opticconnectorization apparatus preferably includes a work table having oneor more registration pins 78. In addition, the automatic fiber opticconnectorization apparatus preferably includes one or moremicropositioners that operate in response to commands by the controller30 for precisely positioning the optical fiber cartridge 34 relative tothe registration pins. As shown in FIGS. 3A and 3B, the automatic fiberoptic connectorization apparatus can also include a solenoid 80 formaintaining the optical fiber cartridge in a fixed position against theregistration pins on the work table once the optical fiber cartridge hasbeen properly positioned by the micropositioner. Due to the design ofthe optical fiber cartridge, the grippers 44 maintain the fiber opticcable parallel to the surface of the work table, thereby permitting thecleaved end face to be perpendicular to the longitudinal axis of thefiber optic cable. In addition, the fiber cleaving unit preferablyincludes horizontal and vertical actuators for controllably positioningthe scribe relative to the fiber optic cable.

[0060] After cleaving each end face of the optical fiber of the fiberoptic cable, the end faces are ground and polished to remove any defectsand to provide the desired shape as shown generally in block 300 of FIG.6A and in more detail in blocks 301-304 of FIG. 6D. According to oneembodiment of the present invention, the automated fiber opticconnectorization apparatus 20 includes an end face polishing unit 81that includes a cassette 82 for preparing the end face of an opticalfiber, such as by grinding, polishing or otherwise cleaning the end faceof the optical fiber. As shown in FIGS. 8A and 8B, the cassette includesa housing b 84 defining a window 86. The cassette also includes a supplyreel 88 and a take up reel 90 disposed within the housing and apreparatory tape 92 extending between the supply reel and the take upreel. For example, the preparatory tape may be a polishing or lappingstrip that includes an abrasive material. Typically, the preparatorytape also includes a cleaning strip that includes a cleaning solution.

[0061] The cassette 82 of this embodiment also includes means fordirecting the tape 92 by the window 86 defined by the housing 84 suchthat the tape will contact the end face 94 of the optical fiber 95.While the directing means can include any type of guides known to thoseskilled in the art, the directing means of one advantageous embodimentincludes a pair of guides 96 positioned on opposite sides of the windowfor directing the preparatory tape in a direction parallel to the frontsurface 84 a of the housing that defines the window. The directing meansof one advantageous embodiment also includes a resilient pad 98,typically formed of a rubber or plastic material, that is aligned withthe window and is disposed interior of the preparatory tape within thehousing. As such, the resilient pad supports the preparatory tape byproviding a backing surface during contact with the end face of thefiber optic cable. In order to protect the preparatory tape and maintainprocess control as the tape advances from the supply reel 88 to the takeup reel 90, the cassette also preferably includes a pair of planarguides 100 inset within the front surface of the housing on either sideof the window and formed of a material, such as a flouropolymer, havinga relatively low coefficient of friction to avoid abrading the tape uponthe inside surface of the cassette which could introduce contaminates tothe tape and, in turn, to the end face of the fiber optic cable.

[0062] The cassette 82 also includes means for advancing the tapefollowing use such that a fresh portion of the tape 92 is presentedwithin the window for grinding, polishing, cleaning or otherwisepreparing the end portion of the next optical fiber. While the tapecould be advanced in a variety of manners, the supply reel and/or thetake up reel of one embodiment of the cassette may include an axle 102that extends outward beyond the housing 84. As such, the axle can berotated following use of the tape to provide incremental advancement ofthe tape.

[0063] The end face polishing unit 81 also includes means forcontrollably moving the cassette 82 relative to the end face 94 of theoptical fiber 95 in response to commands by the controller 30 to therebypolish the end face of the optical fiber. In one advantageous embodimentshown in FIG. 8A, the end face polishing unit includes one and, morepreferably, a pair of actuators 104, such as piezoelectric actuators,mounted on respective sides of the cassette. In order to providemovement of the cassette parallel to the end face of the optical fiberin two mutually perpendicular directions, the pair of actuators shouldbe placed adjacent sides of the cassette that are also perpendicular. Inresponse to predetermined signal patterns provided to the actuators bythe controller, the actuators will move the cassette and, moreparticularly, the tape 92 in a circular, figure eight or other patternas required by the type of optical fiber being polished and the type ofconnector to be mounted upon the optical fiber. Typically, informationdefining the predetermined signal patterns that will be provided by thecontroller to drive the actuators can also be provided by the fiberoptic cable and connector database 26.

[0064] In addition, the cassette 82 could be positioned, typically bymeans of micropositioners that respond to commands from the controller30, to change its direction of contact with the end face 94 of theoptical fiber. For example, a cassette that is otherwise oriented suchthat the tape is in a direction perpendicular to the longitudinal axisof the optical fiber can be tilted either upwards or downwards and/or tothe right or to the left to present a different angle of attack, therebypermitting further control in shaping the resulting end face of theoptical fiber.

[0065] As described below, the same or a similar cassette 82 to thatshown in FIGS. 8A and 8B and described above may be used for applyingcleaning solution and for removing dirt and debris as well as excessadhesive or epoxy from the end face 94 of the optical fiber 95. In thisembodiment, the preparatory tape 92 can include cleaning pads that areprovided in the form of an elongated strip that advances between thesupply and take up reels.

[0066] As shown in FIG. 1, the automatic fiber optic connectorizationapparatus 20 defines an enclosed space within which the optical fiber iscleaved, ground and polished. The cleaving, grinding and polishing of anoptical fiber creates dust and debris which may be classified ashazardous waste. As such, the automatic fiber optic connectorizationapparatus preferably includes a positive pressurization and ventilationsystem, i.e., a vacuum system, for capturing and removing the fiber dustand debris as set forth in blocks b 302 and 304 of FIG. 6D.

[0067] Typically, the automatic fiber optic connectorization apparatus20 performs multiple cleaning and polishing steps. For example, the endface of the optical fiber is typically ground, and is then cleaned toremove dust, dirt and grinding compounds and is finally subjected to oneor more polishing steps in which the end face of the optical fiber ispolished with increasingly finer abrasives in each successive polishingstep. The multiple cleaning and polishing steps can be provided byrepeatably changing the preparatory tape 92 within the cassette 82 or bymoving the optical fiber from station to station, each of which includesa different cassette for grinding, cleaning or polishing the end face ofthe optical fiber.

[0068] After grinding and polishing the end face of the optical fiber,the end face is inspected as shown in block 400 of FIG. 6A. If the endface is not acceptable, the end face is repolished or otherwisereworked, if possible, prior to being re-inspected. If the end facecannot be satisfactorily repolished or otherwise reworked, the fiberoptic cable will be rejected. Once rejected, the fiber optic cable maybe re-cleaved and completely reprocessed. Alternatively, the rejectedfiber optic cable may be discarded.

[0069] As shown in FIG. 2, the automatic fiber optic connectorizationapparatus 20 includes an end face inspection unit 106 (also referred toas an automated optical fiber inspection apparatus) for capturinginterferrograms of the end face of the optical fiber that will beutilized to characterize the geometry of the end face. See block 401 ofFIG. 6E. As described below, typical interferrograms of an end face ofan optical fiber are shown in FIGS. 9A-9D.

[0070] The end face inspection unit 106 includes or is associated withan imaging system 108 for obtaining an image of the end face of theoptical fiber. Preferably, the imaging system obtains and digitizesinterferrograms of the end face of the optical fiber and then stores thedigitized interferrograms in a memory device. See block 402.

[0071] According to one advantageous embodiment shown in FIG. 14, theimaging system 108 includes a scanning camera 110, an interferometer 111and an associated micropositioner 112 for moving the camera inincrements, such as 6 micron increments, in order to scan the surface ofthe end face 94 of the optical fiber 95 at different phase shiftpositions per exposure, such as π/2 phase shift positions per exposure.Thus, the imaging system of this embodiment can generate interferrogramsat each of a number of different phase shifts, such as a hundred or moredifferent phase shifts. For example, FIGS. 9A-9D depict theinterferrograms generated at four different phase shifts, namely, π/2,π, 3π/2 and 2π. For example, one embodiment of the imaging system whichscans at 6 micron increments and can take up to 700 images at a time iscommercially available and is designated as a Physic Instrument (PI)from Nordland Products, Inc. However, the imaging system can includeother frame grabber software, if so desired.

[0072] The intensity measurements for the pixel located at (x,y) in eachof the four interferrograms (I₁, I₂, I₃ and I₄) obtained by the imagingsystem are:

[0073] I₁(x,y), I₂(x,y), I₃(x,y), I₄(x,y)

[0074] In addition to displaying the interferrograms upon a videodisplay 114, the imaging system 108, such as the Physic Instrument fromNordland Products, Inc. or other phase shift analysis software,generates a composite image which is then grey scale normalized to asingle phase pattern as shown schematically in FIGS. 9E and 10. Seeblocks 403-404 of FIG. 6E.

[0075] In order to determine a composite image COMP(x,y) based upon thefour interferrograms, the value representing phase modulo π/2 for eachpixel of the composite image can be calculated by one method as follows:$\Phi = \frac{\left| {{I_{4}\left( {x,\quad y} \right)} - {I_{2}\left( {x,\quad y} \right)}} \right|}{\left| {{I_{1}\left( {x,\quad y} \right)} - {I_{3}\left( {x,\quad y} \right)}} \right|}$

[0076] Since the above function only generates an angular value in thefirst quadrant, each pixel of a composite image having an accurate anglewith a value in the range of 0 to 2π radian, i.e., the phase modulo 2π,is determined by the following table (in which “Phase” represents thevalue of the respective pixel of the composite image) with the actualsigns, i.e., prior to taking the absolute value, of the numerator andthe denominator of taken into consideration as follows: TABLE INumerator Denominator Phase (radian) + + Φ + − π − Φ + ∘ π/2 − + 2π − Φ− − π + Φ − ∘ 3π/2 ∘ − π ∘ + ∘

[0077]FIG. 10 shows the above method applied to calculate the compositeimage at a pixel located at (x,y), i.e., COMP(x,y), based upon theintensity values of pixels from four interferrograms I₁, I₂, I₃ and I₄at the same location (x,y). As also shown in FIG. 10, the compositeimage is typically normalized by converting the phase of each pixel ofthe composite image (0 to 2π) to a corresponding grey scale value (0 to255, i.e., 0 to 2⁸, if there are 8 bits per pixel). In addition, theimaging system subjects the composite image to a rotation invariancetransformation to convert the positional relationship information of thedata set from polar to rectangular for lateral movement of the imagerather than rotational movement, for pattern comparison processing ofthe composite image as known to those skilled in the art. See block 405of FIG. 6E. As shown in FIG. 11, the composite image can also be edgeenhanced prior to the normalization process. For example, the compositeimage shown in FIG. 11A can be edge enhanced to generate the image shownin FIG. 11B. As known to those skilled in the art, the subsequentanalysis of the image, typically by means of fuzzy logic, is facilitatedby edge enhancing the composite image.

[0078] For purposes of illustration, FIGS. 12A and 13A depict compositeimages of the end faces of two different optical fibers. As FIGS. 12 and13 indicate, the composite images provide, among other things,information relating to polishing depth and fiber face contour. Forexample, FIGS. 12B-12D illustrate various contour maps derived from thecomposite image of FIG. 12A. In particular, FIG. 12B is a threedimensional mesh view of the composite image, FIG. 12C is a display ofthe spherical fitting error and FIG. 12D is a surface contour display.As shown, the end face of the optical fiber illustrated in FIGS. 12A-12Dis unacceptable due to the peak on one side of the end face that shouldbe correctable by polishing. Likewise, FIGS. 13B-13D illustrate thevarious contour maps of the composite image of FIG. 13A. In contrast tothe correctable end face of FIGS. 12A-12D, the end face of FIGS. 13A-13Dis not only unacceptable, but is also uncorrectable since one side ofthe end face is deeply pitted, if not fractured.

[0079] The end face inspection unit 106 also includes means forcomparing the image, i.e., the composite image or, more preferably, thenormalized image, of the end face of the optical fiber with predefineddata relating tabto at least one characteristic of the end face of theoptical fiber to automatically determine if the optical fiber isacceptable. This comparison can be performed in several differentmanners without departing from the spirit and scope of the presentinvention. As shown in FIGS. 14 and 15, for example, the composite imagecan be compared to several reference images that have been previouslyclassified as either acceptable or unacceptable. By determining which ofthe reference images is most similar to the composite image, i.e., thebest match, the end face inspection unit and, more particularly, thecomparing means also classifies the composite image as acceptable orunacceptable. See blocks 407-409 of FIG. 6E. By directly inspecting theend face geometry by means of pattern comparison, instead of featureextraction, and by determining the best match instead of an exact match,the comparing means of the present invention greatly simplifies andaccelerates the overall inspection process. The reference images aretypically downloaded to a memory device associated with the end faceinspection unit 106. For example, the reference images can be downloadedfrom an external database 26, such as the fiber optic and connectordatabase. Alternatively, the end face finishing inspection unit caninclude a video camera 116 and a video recorder 118 for recording thereference images of acceptable and unacceptable end faces for subsequentdownloading to a memory device for comparison with the composite image,as shown in FIG. 14. As a result, the inspection criteria can be changedby merely changing the reference images without any alterations to thesoftware which could be quite complex. In addition, the automatic fiberoptic inspection system can include artificial intelligence whichsupplements the reference images to include actual images of the endfaces of some or all of the optic fibers that have undergone inspectionand been classified as either acceptable or unacceptable.

[0080] The end face inspection unit 106 can also include a fuzzy logicwork station 120 for comparing the composite image with the variousreference images to determine if the surface configuration of the endface of the optical fiber is acceptable. Typically, the composite imageis not compared directly to the reference images. Instead, as shown inFIG. 15, the comparing means generally compares a two dimensional fastfourier transform of the composite image to the two dimensional fastfourier transforms of the reference images. Typically, the twodimensional fast fourier transforms of the reference images are alsostored in the memory device of the imaging system 108. In oneembodiment, the fuzzy logic work station includes a NeuralLogix ASD110Fuzzy Pattern Comparator which compares the various reference images tothe composite image to determine the best match. As shown in FIG. 14,both the imaging system and the fuzzy logic work station can have amonitor 122 and a keyboard 124. In addition, the fuzzy logic workstation can have a printer 126. Although illustrated to be separate fromthe central computer 22, the fuzzy logic work station can beincorporated within the computer, if so desired.

[0081] During the construction of the composite image, the imagingsystem, such as the Physic Instrument (PI) by Nordland Products, Inc.,also preferably extracts a number of features relating to the fiberend-face geometry. See block 406 of FIG. 6E. Although the extractedfeatures are not typically utilized during the process of determining ifthe fiber end-face is acceptable as shown in FIG. 18, the extractedfeatures are preferably stored along with other data relating to theparticular optical fiber for subsequent review and/or analysis. In oneadvantageous embodiment, the features extracted from the composite imageinclude: (1) radius of curvature of the end face, (2) spherical-fittingerror, (3) fiber height (protruding or recessed), (4) fiber corediameter, (5) fiber cladding diameter, (6) concentricity of the endface, and (7) fringes within the Region of Interest (ROT) including, atleast, the fiber end-face.

[0082] As shown in Table I, the normalized composite image of theinterferrogram is typically stored in the memory of the imaging system108 along with an identification number, a two dimensional surfaceprofile, the fourier coefficients of the two dimensional surfaceprofile, the various features extracted from the composite image and anindication as to whether the end face of the optical fiber is acceptableor unacceptable, i.e., pass or fail. As such, the automated fiber opticconnectorization apparatus maintains detailed records relating to theconnectorization and inspection of each fiber optic cable. TABLE IIField Field Name Data Type 1 Record I.D. Text/Numeric 2 Interferrogram(Image) OLE Object 3 2D surface profile Binary/Bitmap 4 FourierCoefficients (2D Numeric Image) 5 Radius of Curvature of the Numeric EndFace 6 Spherical fitting Error Numeric 7 Fiber Height Numeric 8 FiberCore Diameter Numeric 9 Fiber Cladding Diameter Numeric 10 Surface SlopeNumeric 11 Diameter of Region of Numeric Interest 12 Pass/FailClassification Yes/No

[0083] In addition to merely determining whether the end face of anoptical fiber is acceptable or unacceptable, the end face inspectionunit 106 also preferably determines if an unacceptable end face can becorrected, such as by further polishing the end face, or if the opticalfiber must be totally reworked or discarded. See block 410 of FIG. 6E.For purposes of illustration, FIGS. 16 and 17 depict the end faces of anumber of optical fibers that include defects that are correctable anduncorrectable, respectively. It should be apparent that data, i.e.,reference images, representative of the various end faces of the opticalfibers of FIGS. 16 and 17 would be compared to the composite image of anunacceptable end face to determine if the defect is correctable.

[0084] In particular, FIGS. 16A-16C shows several end faces havingdefects which fail inspection, but can be repaired by repolishing. Thesedefects include an upwardly protruding lip, scratches and hackle. Eachof these defects can be corrected by the removal of material from theend face, such as with further polishing. In contrast, FIG. 17 showsseveral end faces having defects which cannot be corrected. Thesedefects include a score/indent, a rolloff on one side, a chip out of theside, cracks, a shattered end face and an angled end face. These defectsare not correctable and would require recleaving and completereprocessing.

[0085] The automatic fiber optic connectorization apparatus 20 alsoincludes means for obtaining the components that will be mounted uponthe end portion of the fiber optic cable once the end face of theoptical fiber is found to be acceptable. In particular, the automaticfiber optic connectorization apparatus obtains both the connector partsand the supplies, such as the epoxy, required to mount the specifiedtype of connector upon the end portion of the fiber optic cable. Asdescribed above, the system operator generally provides an indication ofthe type of connector to be mounted upon the fiber optic cable and thefiber optic cable and connector database 26 defines the various partsand supplies required to assemble and mount the specified type ofconnector. According to one embodiment, the automatic fiber opticconnectorization apparatus includes a plurality of mechanical grippersor other types of robotic arms that operate under control of thecontroller 30 for automatically obtaining the various parts and suppliesthat have been previously cleaned and sorted into differentpredetermined bins as shown. Typically, the parts are cleaned byultrasonic and spray methods and are then inspected to insure that theparts are sufficiently clean. Thereafter, the mechanical grippers obtainthe necessary parts from different predetermined bins into which theparts have been sorted or from sequential feed reels as known to thoseskilled in the art.

[0086] The automatic fiber optic connectorization apparatus 20 alsoincludes means, typically including a connector bonding unit 128, forassembling the components upon the end portion of the fiber optic cableonce the necessary parts and supplies have been obtained. In particular,the connector bonding unit generally bonds the ferrule to the endportion of the optical fiber with an epoxy. See block 500 of FIG. 6A. Asknown to those skilled in the art, the epoxy can be two-part resin andcatalyst or a B-stage epoxy depending upon the type of connector to bemounted upon the fiber optic cable. As described above, the type ofepoxy and the placement of the epoxy relative to the optical fiber andferrule is typically defined by the fiber optic cable and connectordatabase 26.

[0087] If a two-part epoxy is utilized to bond the ferrule to theoptical fiber, the connector bonding unit 128 initially inserts theepoxy into the ferrule and the ferrule is then positioned on the opticalfiber such that the end portion of the optical fiber extends through thebore of the ferrule. See blocks 501-502 of FIG. 6F. Preferably, theoptical fiber extends through the bore of the ferrule such that the endface of the optical fiber is aligned with the end of the ferrule asrequired to meet the input performance requirements and connectorassembly parameters provided by the system operator, the wire data listor other source. If the optical fiber is to extend beyond the end of theferrule, the ferrule is then retracted such that the end portion of theoptical fiber extends beyond the end of the ferrule by the desiredamount. If a B-stage epoxy is instead utilized to bond the ferrule tothe end portion of the optical fiber, the connector bonding unit fullyinserts the optical fiber into the ferrule such that the optical fiberneed not later be repositioned.

[0088] As shown in blocks 503-504 of FIG. 6F, the epoxy is then cured,excess epoxy is removed from the end face of the optical fiber, and thecable assembly is inspected. Since most epoxy must be heat cured, theconnector bonding unit typically includes a heater 130 for curing theepoxy. To cure epoxy having a relatively small cure time, such as aB-stage epoxy, the end portion of the optical fiber is held in place andthe heater is positioned near the end portion of the optical fiber forthe required cure time. Alternatively, for epoxy having a relative longcure time, such as two-part liquid epoxy resins, the connector bondingunit may include a separate curing station to simultaneously heat anumber of fiber/ferrule combinations. The connector bonding unitpreferably controls the temperature of the heater and the cure time inaccordance with the data provided by the fiber optic cable and connectordatabase 26. For example, B stage preformed epoxy is generally cured at150° C. for 1 hour. Alternatively, two part epoxy is typically cured byramping the heat up to 80° C. for 1 hour, followed by a heat soak at120° C. for one hour, and a post-cure heat soak at 150° C. for one hour.As known to those skilled in the art, however, some epoxies requiredifferent cure schedules depending on the cable/connector utilization.

[0089] Once the epoxy has been cured, the connector bonding unit 128removes excess epoxy from the end face of the optical fiber, the end ofthe ferrule and other undesirable locations. As described above, theconnector bonding unit can utilize a cassette 82 as shown in FIGS. 8Aand 8B that includes a cleaning strip for cleaning the connectorizedoptical fiber. In one advantageous embodiment, the cleaning strip isimpregnated with a cleaning solution for application to the end face ofthe optical fiber. After the cleaning solution has been applied, wipedand dried, the end face of the optical fiber can be inspected onceagain, such as by means of the imaging system 108 described above or theoptical performance inspection unit 132 described below and shown inblock 600 of FIG. 6A.

[0090] If the end face of the optical fiber is to be concave, theautomatic fiber optic connectorization apparatus 20 preferably furtherpolishes the end face of the optical fiber after the ferrule has beenmounted thereon, but prior to cleaning the end face of the opticalfiber. Since the ferrule is harder than the optical fiber, the abrasivecarried by the polishing strip will preferentially remove material fromthe end face of the optical fiber, thereby forming a concave surface.

[0091] The automatic fiber optic connectorization apparatus 20 and, moreparticularly, the controller 30 also obtains and mounts any additionalconnector parts or hardware that are required pursuant to the fiberoptic cable and connector database 26. See block 601 of FIG. 6G. For a16 gauge connector, for example, the automatic fiber opticconnectorization apparatus would also mount a spring, an outer sleeveand a guide sleeve. For an NTT FC connector, the automatic fiber opticconnectorization apparatus would also mount a barrel, a strain reliefboot, a coupling nut and a strength member retainer.

[0092] Once the additional connector parts have been assembled, the endface of the optical fiber and the connector mounted thereto arepreferably cleaned and a performance inspection is conducted. In orderto conduct the performance inspection, the automatic fiber opticconnectorization apparatus 20 and, more particularly, the opticalperformance inspection unit 132 aligns the opposed ends of the fiberoptic cable 148 with respective ends of a pair of reference opticalfibers extending from a test station 150 and performs an optical lossmeasurement, typically under control of the central computer 22 and/orthe controller 30. See block 602 of FIG. 6G. As shown in FIG. 19, thetest station typically includes an optical source 152 for providingpredetermined optical input to an input optical fiber. In addition tolaunching the predetermined optical input into a first end of theconnectorized fiber optic cable under test as set forth by block 603,the test station also preferably includes a coupler or optical splitter154 for coupling the input optical fiber to a medial portion of a secondoptical fiber having an anti-reflection block 156, such as an indexmatching gel, at one end, and a first detector or power meter 158 at theother end. Thus, the configuration of the test station shown in FIG. 19forms a fiber optic interferometer to permit back reflections from thefiber optic cable under test to be measured by the first detector orpower meter. The test station also preferably includes a second detectoror power meter 160 optically connected to the second end of theconnectorized fiber optic cable under test. See block 604. Based uponthe readings of the first and second detectors, the optical performanceinspection unit can determine the back reflection and optical loss ofthe fiber optic cable/connector assembly as shown in block 605. For mostoptical fibers, the optical loss should be less than 1 dB. The opticalperformance of the optical fiber, including the back reflections andoptical loss, is preferably stored in memory for later display and hardcopy print, thereby further improving the recordkeeping associated withthe connectorization and inspection process.

[0093] Preferably, the optical performance inspection unit includes oneor more micropositioners for automatically aligning the opposed ends ofthe connectorized fiber optic cable to respective ends of the opticalfibers of the test station with the same tolerances as required duringthe mating of a pair of connectors. In this regard, the launchconditions will preferably be {fraction (100/100)}, i.e., 100% of thenumerical aperture of the optical fiber under test and 100% of the corediameter of the optical fiber under test. In order to insure that thetest station is properly calibrated, the test station preferablyperiodically measures the optical loss across a reference cable with aknown loss.

[0094] Although not heretofore described, the product conformityinspection unit 138 preferably checks the components, i.e., the fiberoptic cable and the connector components, prior to the connectorizationprocess to insure that the components meet predefined standards or arewithin acceptable tolerances. See, for example, blocks 251-255 of FIG.6C. Typically, the predefined tolerances and acceptable tolerances areprovided by the fiber optic cable and connector database 26 for avariety of features, such as fiber concentricity, the outer diameter ofthe fiber cladding, the diameter of the fiber core, the inside andoutside diameter of the connector ferrule and the ferrule concentricity.The product conformity inspection unit generally includes a visionsystem, including a camera and associated frame grabber software, forobtaining an image of the various components for subsequent analysis bythe central computer 22 and associated software. In addition toreporting those components which fail to meet specifications as shown inblock 255, the measured features of the various components are alsopreferably stored, thereby generating a statistical database. Bydetermining the physical parameters of the various components of theconnectorized fiber optic cables which ultimately have the best opticalperformance, the automated fiber optic connectorization and inspectionapparatus 20 can also learn to select those components which have thephysical parameters which are generally associated with fiber opticcables that perform acceptably.

[0095] By providing for the automatic connectorization of opticalfibers, the automatic fiber optic connectorization method and apparatus20 of the present invention significantly reduces the time and laborrequired to mount connectors upon the end portions of fiber opticcables, thereby increasing production capacity. As a result, theautomated fiber optic connectorization apparatus can be readily operatedby technicians with very little training. The efficiency and yield ofthe automatic connectorization process of the present invention isfurther advanced by the automated optical fiber inspection apparatus ofone embodiment that insures that the optical fibers have been properlypolished prior to mounting of the connectors and, if an optical fiber isunacceptable, automatically determines if the optical fiber must berepolished or otherwise reworked. In contrast to conventional automatedconnectorization techniques, the automated fiber optic connectorizationapparatus of the present invention can advantageously mount any one of aplurality of types of connectors upon the end portion of a fiber opticcable based upon input by the system operator or other source, therebypermitting rapid customization of the automated fiber opticconnectorization apparatus.

[0096] Many modifications and other embodiments of the invention willcome to mind to one skilled in the art to which this invention pertainshaving the benefit of the teachings presented in the foregoingdescriptions and the associated drawings. Therefore, it is to beunderstood that the invention is not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

That which is claimed is:
 1. An automated fiber optic connectorizationapparatus for mounting a connector upon an end portion of an opticalfiber, the automated fiber optic connectorization apparatus comprising:a memory device for storing data relating to a plurality of types ofconnectors; a controller, operably connected to said memory device, forreceiving input that specifies the type of connector to be mounted uponthe end portion of a fiber optic cable, wherein said controllerautomatically determines components that will be required to mount thespecified type of connector upon the end portion of the fiber opticcable based upon data stored by said memory device; means, responsive tosaid controller, for automatically obtaining the components determinedby said controller to be mounted upon the end portion of the fiber opticcable; and means, responsive to said controller, for automaticallyassembling the components obtained by said automatic obtaining meansupon the end portion of the fiber optic cable such that the specifiedtype of connector is mounted thereon.
 2. An automated fiber opticconnectorization apparatus according to claim 1 wherein said memorydevice stores data defining the parts and supplies required to assembleeach type of connector.
 3. An automated fiber optic connectorizationapparatus according to claim 1 wherein said controller also receivesinput that specifies the length of the resulting fiber optic cable, andwherein the automated fiber optic connectorization apparatus furthercomprises a cutter, responsive to said controller, for automaticallycutting the fiber optic cable to length.
 4. An automated fiber opticconnectorization apparatus according to claim 1 wherein said controlleralso receives input that specifies the geometry of an end face of anoptical fiber of the fiber optic cable, and wherein the automated fiberoptic connectorization apparatus further comprises means, responsive tosaid controller, for automatically polishing the end face of the opticalfiber of the fiber optic cable to the specified geometry prior tomounting the connector upon the end portion of the fiber optic cable. 5.An automated fiber optic connectorization apparatus according to claim 4further comprising means, responsive to said controller, forautomatically inspecting the optical fiber after polishing the end faceof the fiber optic cable prior to mounting the connector upon the endportion of the fiber optic cable.
 6. A method for automatically mountinga connector upon an end portion of an fiber optic cable, the methodcomprising the steps of: providing a memory device for storing datarelating to a plurality of types of connectors; receiving input thatspecifies the type of connector to be mounted upon the end portion ofthe fiber optic cable; automatically determining components that will berequired to mount the specified type of connector upon the end portionof the fiber optic cable based upon data stored by the memory device;automatically obtaining the required components to mount the specifiedtype of connector upon the end portion of the fiber optic cable; andautomatically assembling the components upon the end portion of thefiber optic cable such that the specified type of connector is mountedthereon.
 7. A method according to claim 6 wherein said providing stepcomprises providing a memory device for storing data defining the partsand supplies required to assemble each type of connector.
 8. A methodaccording to claim 6 wherein said receiving step comprises receivinginput that specifies the length of the resulting fiber optic cable, andwherein the method further comprises the step of automatically cuttingthe fiber optic cable to length.
 9. A method according to claim 6further comprising the step of automatically polishing an end face of anoptical fiber of the fiber optic cable prior to said assembling step.10. A method according to claim 9 further comprising the step ofautomatically inspecting the optical fiber after polishing the end faceof the optical fiber prior to said assembling step.
 11. An automatedoptical fiber inspection apparatus for inspecting an end face of anoptical fiber, the automated optical fiber inspection apparatuscomprising: a memory device for storing predefined data relating to atleast one characteristic of the end face of an optical fiber; an imagingsystem for obtaining an image of the end face of the optical fiber; andmeans, responsive to said imaging system, for comparing the image of theend face of the optical fiber with the predefined data relating to atleast one characteristic of the end face of an optical fiber toautomatically determine if the optical fiber is acceptable.
 12. Anautomated optical fiber inspection apparatus according to claim 11further comprising means, responsive to said comparing means, forautomatically determining if the end face of an unacceptable opticalfiber can be corrected.
 13. An automated optical fiber inspectionapparatus according to claim 11 wherein said memory device stores datarepresentative of images of acceptable end faces and unacceptable endfaces.
 14. An automated optical fiber inspection apparatus according toclaim 11 further comprising a test station for determining the opticalperformance of optical fiber.
 15. A method for automatically inspectingan end face of an optical fiber, the method comprising the steps of:providing a memory device for storing predefined data relating to atleast one characteristic of the end face of an optical fiber; obtainingan image of the end face of the optical fiber; and comparing the imageof the end face of the optical fiber with the predefined data relatingto at least one characteristic of the end face of an optical fiber toautomatically determine if the optical fiber is acceptable.
 16. A methodaccording to claim 15 further comprising the step of automaticallydetermining if the end face of an unacceptable optical fiber can becorrected.
 17. A method according to claim 15 wherein said providingstep comprises providing a memory device for storing data representativeof images of acceptable end faces and unacceptable end faces.
 18. Amethod according to claim 15 further comprising the step of testing theoptical fiber to determine the optical performance of the optical fiber.19. An optical fiber cartridge assembly comprising: an optical fibercartridge comprising: a platform; a reel rotatably mounted upon saidplatform; and first and second gripping means, mounted upon saidplatform, for holding first and second opposed ends of an optical fiber,respectively; and means for rotating said platform relative to said reelsuch that the optical fiber is wound about said reel.
 20. An opticalfiber cartridge assembly according to claim 19 wherein said opticalfiber cartridge further comprises means for raising said reel relativeto said platform during rotation of said platform relative to said reel.21. A cassette for preparing an end face of an optical fiber, thecassette comprising: a housing defining a window; a supply reel and atake up reel disposed within said housing; a preparatory tape, advancingbetween said supply reel and said take up reel, for preparing the endface of the optical fiber; and means for directing said tape by thewindow defined by said housing such that said tape contacts and preparesthe end face of the optical fiber.
 22. A cassette according to claim 21wherein said preparatory tape is selected from the group consisting of apolishing strip and a cleaning strip.
 23. A cassette according to claim21 wherein said directing means comprises a resilient pad aligned withthe window defined by said housing and disposed interior of saidpreparatory tape within said housing for supporting said preparatorytape during contact with the end face of the optical fiber.
 24. Acassette according to claim 21 further comprising means for controllablymoving said housing relative to the end face of the optical fiber.
 25. Acassette according to claim 21 further comprising means for advancingsaid tape by the window defined by said housing.